The history of Castle&Key distillery can be traced back to the early 19th century, founded by one of the pioneers of the American spirits industry and located in Frankfurt, Kentucky, at the center of the bourbon whiskey producing region. It is not only known for its handmade spirits, but also for its exquisite craftsmanship.

The distillery was built in the late 19th century and its style complements European architectural design, featuring a castle, a spring house, and a sunken garden. The distillery has been carefully restored to showcase its historical heritage. Since its reopening in 2018, the leadership of the distillery has earned a good reputation for its forward-looking, innovative, and modern sustainable development practices.

Due to plans to build a new bottling plant near the warehouse in Versailles, the brewery has decided to strategically invest in a large-scale solar photovoltaic project. In addition to reducing Castle&Key's carbon footprint and lowering long-term energy costs, solar energy will also set a precedent for the Kentucky liquor industry to adopt renewable energy. However, integrating photovoltaic services into historical sites faces unique challenges, ranging from aesthetic considerations and protection requirements to practical issues of power generation in production facilities.

From concept to final implementation, the entire process requires strategic planning, close collaboration with partners, and creative problem-solving. The timing is crucial as the $2 million grant provided by the US Department of Agriculture's Rural Energy Program (REAP) will expire at the end of the year.

Challenge: Integrating modern sustainability into archaeological sites

Castle&Key sees the expansion of its bottled business as an excellent opportunity to achieve more sustainable operations. At present, the distillery is served by Louisville Gas and Electric Company and Kentucky Public Utilities, both of which heavily rely on coal and natural gas. The distillery realizes that self generating electricity can achieve cost stability while also having a significant impact on the environment.

The brewery collaborates with local installer Solar Energy Solutions (SES) to design and construct on-site systems.

From the beginning, the project faced urgent deadline challenges. In order to obtain tax credits and maximize the use of REAP grants, the first half of the solar cell array must be installed, powered on, and inspected before December 31, 2024. The urgency of time means that any delay at any stage - whether it's design, component supply, or utility approval - could jeopardize millions of dollars in fiscal incentives.

Technical barriers also urgently need to be addressed. The photovoltaic system must be carefully designed to integrate with the operating system of the brewery and connect to the public grid under strict safety standards, especially considering the flammable spirits stored on site. Only after the inspectors confirm that the system meets all specifications can the operating permit be obtained. In addition, Castle&Key hopes that the system will be robust enough to operate reliably for decades, which requires careful consideration of component durability, maintenance requirements, and scalability for the second phase of construction.

Solution: Utilize mature professional knowledge and suppliers

SES has 20 years of industry experience, leveraging its advantage as a vertically integrated engineering, procurement, and construction (EPC) company to provide turnkey solutions. This internal operational model ensures accountability and coordination during the rapid construction process of Castle&Key distillery. The distillery did not adopt a closed system, but chose to stay connected to public facilities in order to sell excess electricity and ensure power supply in adverse weather conditions such as cloudy or snowy days.

The key to SES's solution lies in its collaboration with Weidmuller. Weidmuller has been supplying photovoltaic modules to the international market for 15 years. Its US subsidiary, Weidmuller USA, located in Richmond, Virginia, has been commissioned to provide the required photovoltaic DC combiner boxes by the end of the year for rapid delivery and timely installation. Weidmuller USA ensures that SES has the necessary cabinets on site to complete wiring, connections, and testing before the critical year-end power on.

These combiner boxes bundle multiple DC strings from solar panels together, protected by integrated fuses and surge protectors, and provide a single aggregated power supply for the inverter. By simplifying system design, Weidmuller devices not only save time, but also provide a durable solution - with a five-year warranty - for long-lasting durability.

SES and Weidmuller's technical teams closely coordinated on design specifications, including adjusting the number and configuration of strings. The modular structure of these enclosures provides flexibility between the initial stage and the next stage of expansion, ensuring smooth system expansion. Although the initial installation did not include the widely used string monitoring feature in Europe and Latin America, if Castle&Key requires more detailed performance monitoring, Weidmuller provides later modification options that can be added. Given that solar panels are exposed to extreme weather conditions during their lifespan, the string monitoring function helps to accurately locate faulty panels or modules.

Result: Use of clean energy

Castle&Key's first solar project has a scale of 1.2 megawatts of direct current and aims to provide 960 kilowatts of alternating current to meet its liquor production needs. The second phase project is under development, aiming to provide an additional 600 kilowatts of electricity for the brewery.

By managing schedules, providing powerful equipment, and ensuring seamless integration with the power grid, SES provides a system that enables Castle&Key to achieve sustainable development goals and financial incentives.